Multi-paneled protective undergarment

ABSTRACT

A protective undergarment ( 10 ), shown in the form of shorts, includes integrally formed protective panels ( 22, 26, 30 ) that exhibit slash-proof properties. The protective areas ( 22, 26, 30 ) are made from a flexible Kevlar® knit or the like, and extend to cover the groin, crotch, substantial areas of the buttocks and the inner thigh regions of both legs. The protective panels ( 22, 26, 30 ) are externally snitched to a low thermal burden material ( 18, 20 ), such as a polyester mesh, that provides elasticity and completes the structure of the shorts ( 10 ). The Kevlar® knit is flexible and preferably lies directly against the skin of a user to provide blast wave and ballistic fragment deflection whilst permitting mobility in a lightweight arrangement. Varying thickness of the Kevlar® knit can be used in the protective areas ( 22, 26, 30 ) selectively to enhance protection against blast wave and fragment penetration. The shorts ( 10 ) find particular application in battlefield theatres where military personnel are exposed to bomb threats.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 12/948,183, entitled “Multi-Panelled Protective Undergarment,”filed on Nov. 17, 2010, which is herein incorporated by reference in itsentirety.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

This invention relates, in general, to multi-panelled protectiveundergarments and is particularly, but not exclusively, applicable toflexible reinforced undergarments such as abdominal body armour (in theform of trunks or shorts) which includes protective, armour-like areasfor the groin, buttocks, crotch and upper thighs.

2. Background of the Invention

With great regret, a rise in worldwide terrorism has seen an increaseduse of improvised explosive devices (“IEDs”); these are also known asroadside bombs due to their deployment. Such IEDs essentially contain anexplosive attached to a detonating mechanism, and cause severe externaland internal body traumas from several effects, principally: the blastpressure wave and the fragmentation effect. The fragmentation effectleads to penetrating ballistic or blunt force injuries that arise fromimpacts with projectiles included in the container, projectiles producedfrom the destruction of the container and from objects surrounding thedetonator and target.

IEDs are therefore of considerable concern and present a real threat toboth civilians and, more particularly, military or police personnel.

With respect to likely injuries sustained in an explosion, primary blastinjury is a direct result of the over-pressurization waves' impact onthe body. These injuries occur mainly to the gas-filled organs,including the gastrointestinal systems and colonic track, and arise (forexample) from the blast wave being channeled into the body.Particularly, injuries result from spalling, implosion, inertia and theextreme pressure differentials at the body surfaces causing a stresswave that is produced in the underlying tissues. Also, IEDs can causetraumatic amputation (of a leg or genitalia) and potential bleed-outwhen a body-part is severed following an explosion. Indeed, with respectto leg injuries, the location of the femoral artery in the upper leg andthe overall circumference of the thigh often inhibit the application ofa tourniquet used conventionally and initially to stem the flow oftraumatic bleeding in advance of surgery.

Protection of the groin, crotch region, buttocks and upper thigh aretherefore equally important, but conventional plate-armour, besidesbeing heavy, is generally considered restrictive of movement to theextent that a soldier's effectiveness may be compromised in that theyare unable to run or crouch easily (when wearing such plate-basedarmour).

The U.S. Navy's BUAER (Bureau of Aeronautics) “Flak Shorts” were madefrom ballistic nylon and protected the groin and lower abdomen from lowvelocity fragments (see: http://www.vietnamgear.com/kit.aspx?kit=659).They had a front zip closure protected by a snap fastener cover andfeatured an adjustable crotch strap. The BUAER shorts were worn with amatching vest by Navy and Marine Corps aircrews early in the VietnamWar. Often referred to as “Flak Diapers”, the weight (approximately 3lbs or about 1.3 kg) and overall size of these flak diapers meant thatthey were rarely worn and, more often than not, were instead used as acushion to protect air-crewmen against ground fire.

Imperial Armour SA has also marketed “ballistic underwear” (seehttp://www.youtube.com/watch?v=ipDrFc7Zqnk). Four-ply unidirectionalfibre is cross-plied and sandwiched into a flexible film that is cutinto a specific pattern. The resulting “ballistic panel” is combinedwith a trauma sheet that is worn next to the body. The trauma sheettherefore defines a tailored article of clothing having a pocket intowhich the ballistic panel is inserted. The cumulative weight of theproduct is in the region of 1.6 kg. The multiple layers are heatretaining, especially since trapped air acts as a thermal insulator.

In terms of leg wear design, cycling shorts are skin-tight leg weardesigned to improve comfort and efficiency while cycling. Particularly,they: i) reduce wind resistance and thereby increase aerodynamicefficiency; ii) protect the skin against the repetitive friction of thelegs against the bicycle seat or frame; iii) draw sweat away from theskin to prevent chafing and rashes, and to cool the rider down throughthe process of evaporation; iv) compress the legs, which can help combatmuscular fatigue. The traditional chamois leather patch inside theshorts in the crotch area (which corresponds to the saddle region on thebike) remains popular, although synthetic chamois linings are nowproduced in a variety of shapes and styles to suit the needs ofdifferent rider. However, patch designs are minimized to reduce overallweight and to provide a smooth surface that is aerodynamicallyoptimized. Modern cycling shorts are often made of stretchable spandex(Lycra® fibre), with the hem of each leg usually lined with elasticand/or elastic gel that clings to the skin keeping it in a fixedposition.

By way of example, the Black Pearl Bike short (by Aero Tech Designs) ismade from tricot fabric that is highly aerodynamic and hydrodynamic. Themicrofiber nylon is 87% micro-denier nylon and 13% spandex, with thecompression supporting muscles and movement to reduce muscle fatigue andlactic acid buildup. The material blend of nylon fibers allows for asoft feel that dries quickly. A shock absorbing cellular urethane(“open-cell” structure) pad is designed to absorb shock while allowingwater vapor and perspiration to move through the open cells and thusaway from the body. Pads in cycling shorts can be both anti-bacterialand hypoallergenic, thereby resisting odors and reducing germ growth.

However, cycling shorts provide no protection against trauma and merelyprevent chaffing and localized soreness arising from friction rubbingand related friction burns.

BRIEF SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided amulti-panelled protective undergarment comprising: a ballistic resistantprotective panel forming one panel of the undergarment; and a lowthermal burden material snitched to the ballistic resistant resistivepanel, the low thermal burden material forming complementary fabricpanels of the undergarment; wherein the ballistic resistant panel andthe low thermal burden material in combination structurally assembleinto the undergarment.

Advantageously, the preferred embodiments provide a fully-flexibleundergarment that exhibits anti-ballistic properties whilst beinglightweight and allowing good leg mobility. The improved integral designof the protective undergarment ensures that a blast-protective,slash-proof (or “ballistic resistant”) patch remains in place to protectthe lower abdomen and especially the crotch, groin, inside regions alongthe upper thigh and significant areas around/of the buttocks. Theundergarment of the preferred embodiments therefore offers increasedprotection to the common iliac artery, the external and internal iliac,and the femoral artery (as well as the profunda femorus and superficialfemoral artery).

Preferably, the protective patch is of unitary construction and isexternally stitched to a low thermal burden material, such as polyestermesh, that provides both a low thermal burden effect and elasticsupport. Front and back regions of the protective patch are typicallynot symmetrical, with a rear portion having a larger area that extendssubstantially across the buttocks.

In a preferred embodiment, the slash-proof material is realized byknitted Kevlar®. To reduce potential for skin irritation throughrubbing, the protective panels are externally stitched to the lowthermal burden material that completes the structure of the shorts. TheKevlar® knit is flexible and preferably lies near to (or directlyagainst) the skin of a user to provide blast wave and ballistic fragmentdeflection whilst is limited overall areas permit mobility in theresultant lightweight undergarment.

These and other objects and features of the present invention willbecome more fully apparent from the following description and appendedclaims, or may be learned by the practice of the invention as set forthhereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of thepresent invention, a more particular description of the invention willbe rendered by reference to specific embodiments thereof which areillustrated in the appended drawings. It is appreciated that thesedrawings depict only illustrated embodiments of the invention and aretherefore not to be considered limiting of its scope. The invention willbe described and explained with additional specificity and detailthrough the use of the accompanying drawings in which:

FIG. 1 is a front view of protective trunks according to a preferredembodiment of the present invention;

FIG. 2 is a rear view of the protective trunks of FIG. 1; and

FIG. 3 is a front perspective view of the protective trunks of FIG. 1,the view showing further detail of supporting low thermal burden fabric.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

Turning to FIGS. 1 to 3, there are shown various views of protectivetrunks 10 according to a preferred embodiment of the present invention.The terms “trunks” is not limiting and should be understood to include,and be interchangeable with, equivalent terms such as “boxers”,“briefs”, “shorts”, “diapers” and “underpants”.

The protective trunks 10, in a preferred embodiment, resemble cyclingshorts in that legs 12, 14 extend, when worn, down the thighs of a userto close slightly above the knee and thus around the quadriceps andhamstrings of a wearer. A waistband 16 extends around the top of thetrunks 10, which waistband is either elasticated and/or otherwisepermits for fitting adjustment. At the front, beneath the waistband 16,a relatively narrow (but optional) waist panel 16 connects the waistband16 to: i) outer leg side coverings 20; and ii) a front adnominalprotective panel 22. At the back, beneath the waistband 16, a relativelynarrow (but optional) lateral back panel 24 connects the waistband 16to: i) the outer leg side coverings 18; and ii) a rear buttockprotective panel 26 that extends across the buttocks and which extendsdownwardly to merge or connect to the front adnominal protective panel22 in a saddle or crotch region 28.

The waist panel 18 and lateral back panel 24 therefore provide someflexibility in a torso region of the trunks 10, since these panels andthe outer leg side coverings 18 are preferably made from a low thermalburden material, such as a polyester mesh or a combination of nylon andLycra (or the like) which, also, preferably has good wicking properties.The waist panel 18, lateral back panel 24 and outer leg side coverings18 function to compress the legs and tummy to help combat muscularfatigue and, furthermore, permit the trunks both to “breath” and toexpress perspiration (in the form of water vapour) through a coolingevaporative effect from the surface thereof. The waist panel 18, lateralback panel 24 and outer side legs may be formed of individual piecesthat are stitched together or otherwise formed as larger,multi-functional pieces.

In addition to the front adnominal protective panel 22 and rear buttockprotective panel 26, inside thigh protective panels 30 attach around thecrotch region 28 and further attach, typically along as external seam,to outer leg side coverings 18 to form short trouser legs. The insidethigh protective panels 30 therefore extend along the inside of thethigh and join to (amongst other elements) the outer leg side coveringsalong seams 32 (shown in dotted outline in FIGS. 1 and 2).

From a constructional perspective, the front adnominal protective panel22, rear buttock protective panel 26 and inside thigh protective panels30 (which may collectively be formed as a single piece or otherwise inparts) are manufactured from an anti-ballistic or slash-proof material.For example, the protective panels may be made from a slash-proofmaterial that complies with at least British Standard (BS) EN 388-6.2blade cut level 2. In light of forming the protective panels (referencenumerals 22, 26 and 30 in the figures) as an integral part of the trunk10, there is no possibility for any of the protective panels tosubstantially move away from their intended positions within thegarment; this contrasts with the prior arrangements where armour eitheris incorporated into a pouch or pocket or where a padding or lining isstitched into a pre-existing trouser. The protective panels thereforeprovide blast protect to the lower abdomen and especially the crotch,groin, inside regions of the upper thighs and significant areas of oraround the buttocks. Indeed, in contrast with prior art systems thatmake use of downward hanging armour panels that only protect the groinregion from lateral impacts arising from frontal assault, the protectivepanels of the preferred embodiments extend at least under the crotch andaround the front and rear areas of the lower abdomen (i.e. groin andbuttocks) and thus provide protection against blasts (e.g. from IEDs)from ground level.

Although FIGS. 1 to 3 show the front adnominal protective panel 22 andrear buttock protective panel 26 as being generally U-shaped, cup-shapedor chalice-shaped, their exact shape is determined from the degree ofprotection that is desired for the underlying body parts. That said, tomaintain flexibility of movement, the protective panels generally onlycover the vital arteries and organs in the lower belly/upper groin andalso the genitalia. For example, the preferred arrangement for theinside thigh protective panels 30 of the trunks 10 offers increasedprotection to the common iliac artery, the external and internal iliac,and the femoral artery (as well as the profunda femorus and superficialfemoral artery). Typically, therefore, the inside thigh protectivepanels 30 will be strip-shaped and surround about one-third of the leg.The rear buttock protective panel 26, in contrast with conventionalbriefs or boxer shorts, extends across the buttock regions to inhibitthe effects of explosion shockwaves that otherwise enter the analpassage and which might cause significant harm to the colon.

In a preferred embodiment, the protective panels 22, 26 and 30 are madefrom knitted Kevlar® having a thickness of between about 2 mm and 3 mm.Different protective panels can have different thicknesses of thisslash-proof material, e.g. front adnominal protective panel 22 for thegroin region typically is made thicker than the inside thigh protectivepanels 30. In terms of slash-proof materials, the fabric “Quality K2815”by Dale Techniche with a weight of 360/380 grams per square metre (gsm)is one suitable material, with Quality K2815 being a heavier modifiedinterlock knit fabric that is flame retardant and made from 100% Kevlar®fibre. While not wishing to be bound by theory, it is understood thatthe knitted configuration of Kevlar® has an increased shrapneldeflecting ability because the threads resist separation as compared toconventional materials in which the warp and weft are more easily teasedapart (and thus penetrated) by ballistic fragments.

In other embodiments, alternative anti-slash/anti-ballistic materialsother than Kevlar® may be used, which other materials may includeUltra-High Molecular Weight Polyethylenes (UHMwPE), such as Dyneema®.Multiple stacked layers (typically at least three) of silk twill orknitted silk having a weave weight of 100 gsm have also been found toperform, with natural fibres having an inherent advantage with respectto their ability to take up and dissipate water, i.e. their naturalwicking capabilities. Also, in the event that the trunks are compromisedby fragment damage, the generally inert nature of (clean) silk in bodytissue is a known medical quantity.

To extend further the concept of using silk, a preferred embodimentmakes use of silk (or another naturally strong material) to form boththe low thermal burden (“support”) material that forms, for example, theouter thigh areas and also thicker knitted or woven areas of silk forthe protective areas 22, 26, 30. In this way, the trunks 10 have varyingmaterial weights of silk covering different body regions. For example,the areas of the trunks designed with a lower thermal burden (seen inFIGS. 1 and 2 as the darker/black areas) may therefore be composed fromsilk with a weight of between about 75 gsm and 115 gsm, with theprotective panels 22, 26, 30 realized by layers of this same silkmaterial that combine to produce an effective protective panel weight ofsilk in the region of between about 250 gsm and about 450 gsm and morepreferably in the region of about 300 gsm to about 400 gsm. Knitted silkwould provide for some degree of natural elasticity. Fitting of asilk-based trunk about the waist (and legs) could make use of a drawstring and/or a corset-based cross-fastening to drawing the truck aboutthe leg. Alternatively, a small percentage of an elastic fibre could beincluded in the weave/knit.

The mix of protective slash-proof materials and wicking materials thatassemble to define the shape of the trunks 10 provides the wearer with acomfortable fit that has a degree of self-heat regulation and sweatdissipation. The breathability of the polyester mesh or a combination ofnylon and Lycra (or the like) therefore offsets the generally higherthermal insulative properties of, for example, the Kevlar® knit.

It is preferred that the trunks 10 have no opening or “fly”.

Protective panels (and, if desired, the wicking material) can be treatedwith both anti-bacterial and hypoallergenic agents (includingsilver-based compounds), thereby resisting odors and restricting thepotential for bacterial or fungal growth.

In one particular embodiment, the protective patch may be furthercovered with a soft material membrane that, in use, lies against theskin and acts to commute perspiration away from the skin. Such a linermay be coated with an anti-microbial agent or anti-odour agent, with theliner being either fixed or removable from the protective patch. Thelining can also act to reduce sensitivity. Other embodiments may beunlined but additional coverings represent an additional weight and anincreased thermal burden.

The protective panels may be cut from a singular sheet of material,although another embodiment makes use of panels that are double-stitchedtogether along peripheral edges of each panel. Stitching together of thevarious pieces of the trunks 10 is preferably realized by external flatstitching and an external seam that reduce opportunities for internalstitches to rub against bare skin.

It will, of course, be appreciated that the above description has beengiven by way of example only and that modifications in detail may bemade within the scope of the present invention. For example, the precisecomposition of the supporting wicking material need not exactly follow anylon-spandex mix, with the material rather needing to be strong, soft,durable and elastic. Also, in terms of overall length of the leg, it ismerely preferred that the tight-fitting leg extends to above the kneewith an opening generally surrounding the quadricep muscle andhamstring. The length of the leg of the undergarment could optionally beshorter or longer than that shown in the accompanying drawings, with theprotective patch covering at least a sizeable portion of the insidethigh to provide protection of the upper track of the femoral artery inthe leg.

Indeed, whilst a preferred embodiment refers to shorts, the principal ofintegrating one or more slash-proof regions (preferably in the form of aKevlar knit or the like) with a elasticized wicking cloth can be appliedto other undergarments, including vests or T-shirts, that selectivelytarget blast protection of arteries (such as the axillary, anteriorhumeral circumflex, profunda brachii and brachial arteries) in the upperarm and shoulder.

While various embodiments of the present invention refer to use of a“wicking material”, it is envisioned that this fabric, whilst preferablysupporting a wicking effect, need not accomplish any wicking effectwhatsoever. More importantly, however, is that the material surroundingthe protective panels has a low thermal burden and, preferably, also bea strong and lightweight support fabric. The term “wicking” shouldtherefore be viewed in this context.

The terms “anti-ballistic” or “ballistic resistant” should be construedin the sense of a strengthened material knit or weave that deflects orimpedes ballistic fragment penetration, with the term “slash-proof”representing one type of material that is suitable for application inthis context.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the invention is, therefore, indicatedby the appended claims rather than by the foregoing description. Allchanges which come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

1. A protective undergarment incorporating at least one ballisticresistant protective panel selectively located and integrated into theundergarment to cover, in use, at least one body region selected fromthe group consisting of: the lower abdomen; the crotch; the upper groin;the genitalia; the lower belly; inside regions of the upper thighs; andthe buttocks; wherein said at least one ballistic resistant protectivepanel presents an area of relatively high thermal burden within theundergarment and wherein the undergarment further includes a relativelylow thermal burden material providing structure to the undergarment andwherein at least one area of relatively low thermal burden material doesnot enjoy anti-ballistic protection afforded by said at least oneballistic resistant protective panel.
 2. The protective undergarment ofclaim 1, wherein the ballistic resistant protective panel is knittedKevlar®.
 3. The protective undergarment of claim 2, including multipleprotective panels.
 4. The protective undergarment of claim 3, whereinthe low thermal burden material is selected from the group consistingof: a polyester mesh; a nylon-Lycra® mix; and silk.
 5. The protectiveundergarment of claim 1, wherein the ballistic resistant protectivepanel complies with BS EN 388-6.2 blade cut level
 2. 6. The protectiveundergarment of claim 1, wherein the ballistic resistant protectivepanel and the low thermal burden material are silk based, the resistantprotective panel realized by relatively thick with a gsm weight that isat least double that of the low thermal burden material.
 7. Theprotective undergarment of claim 2, wherein the Kevlar has a covering.8. The protective undergarment of claim 2, wherein theballistic-resistant protective panel is stitched to the undergarment. 9.A protective undergarment incorporating at least one ballistic resistantprotective panel selectively located and structurally integrated intothe undergarment to protect, in use, one or more body regions selectedfrom the group consisting of: the lower abdomen; the crotch; the uppergroin; the genitalia; the lower belly; inside regions of the upperthighs; and the buttocks; wherein said at least one ballistic resistantprotective panel presents an area of relatively high thermal burdenwithin the undergarment and wherein the undergarment further includes arelatively low thermal burden material covering at least one area thatdoes not enjoy anti-ballistic protection afforded by said at least oneintegrated ballistic-resistant protective panel.
 10. The protectiveundergarment of claim 9, wherein the ballistic resistant protectivepanel is knitted Kevlar®.
 11. The protective undergarment of claim 10,including multiple protective panels.
 12. The protective undergarment ofclaim 11, wherein the low thermal burden material is selected from thegroup consisting of: a polyester mesh; a nylon-Lycra® mix; and silk. 13.The protective undergarment of claim 9, wherein the ballistic resistantprotective panel and the low thermal burden material are silk based, theresistant protective panel realized by relatively thick with a gsmweight that is at least double that of the low thermal burden material.14. The protective undergarment of claim 10, wherein the Kevlar has amaterial cover.
 15. The protective undergarment of claim 10, wherein theballistic-resistant protective panel is non-removable from theundergarment.
 16. A protective undergarment incorporating at least oneballistic resistant protective panel selectively located and integratedinto the undergarment to cover, in use, at least one body regionselected from the group consisting of: the lower abdomen; the crotch;the upper groin; the genitalia; the lower belly; inside regions of theupper thighs; and the buttocks; wherein said at least one ballisticresistant protective panel is non-removably attached or bonded to clothsupport material that together, in combination, thereby form theundergarment and wherein at least one area of cloth support material inthe undergarment is not layered with the said ballistic resistantprotective paneling.
 17. The protective undergarment of claim 16,wherein said at least one ballistic resistant protective panel isknitted Kevlar®.